ASME (American Society of Mechanical Engineers) is a leading developer of codes and standards in the mechanical engineering community. ASME code section VIII details mandatory rules regarding vessel design, including engineering, manufacturing, and testing of pressure vessels. These standards enhance public safety and health as well as promote quality and innovation. Here are the main parameters outlining ASME construction of pressure vessels with supporting ASME testing requirements.
Parameters such as wall thickness, material, and flange rating are determined by the application, including pressure, temperature, corrosion allowance, and fluid flow. These conditions are calculated and reviewed/approved by the ASME inspector when required per code. Stainless, Hastelloy, AL6XN, duplex, and Inconel materials are ASME-approved materials for pressure vessel construction in the pharmaceutical, life sciences, and health-related industries, of which Apache is qualified to fabricate.
ASME standards also define the quality, type, and finishing of the welds. Head styles (ASME F&D, 80:10, 2:1 Elliptical), seams, nozzles, manways, and other components are designed per ASME Code. Applicable ASME Code welding procedures must be followed using certified ASME welders to maintain the structural integrity of an ASME pressure vessel. Welders must be certified to a qualified weld specification qualified per ASME code guidelines.
Gauges, valves, pressure outlets, and drainage are required safety components in ASME design pressure vessels. The proper selection of components and design is critically important to the safety and performance of the ASME vessel. The selection of safety components needs to be evaluated closely to define the required scope of supply.
There is another ASME specification to ensure the quality and safety of parts used in pharmaceutical, bio-processing, and other industries requiring a hygienic vessel, called ASMP-BPE. BPE (Bio Processing Equipment Standard) specifies the surface finishes RA (roughness average) requirements and pickle passivation and electropolishing requirements.
Tests & Certification
There are significant testing, certifications, and documentation requirements for ASME compliance and satisfying the numerous customer requirements. Many require ASME inspection as well as a TOP (turnover packet). Some ASME testing and certification requirements include pneumatic, hydrostatic, liquid penetrant, saline, riboflavin, CIP coverage, material, base metal thickness, material trace, welder trace, Ferroxyl, PMI (Positive Material Identification) radiography, and UT.
Apache has been ASME certified for over 40 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.
As the Cannabis Processing industry continues to evolve, increasing regulations are following. With continuous new products and additive combinations entering the market, the sale and distribution of the products will have more regulations. The processing and production of CBD and cannabidiol components are already seeing increasing standards.
When searching for a new Cannabis Processing or Extraction vessel equipment supplier, ask these five questions:
Apache Stainless is a manufacturer of sanitary, highly engineered, ASME pressure vessels for a multitude of industries, including cannabis processing, pharmaceutical, health and biopharma. We have served the Cannabis and CBD processing industry several years with processing tanks, hydrocarbon extraction tanks, mixing tanks and separating vessels. We also design and manufacture vessels with Canadian Registration Numbers (CRN) for all Canadian provinces. We have all Stainless ASME certified manufacturing facility with custom capabilities including heat exchange surfaces, agitation, CIP (clean-in-place) componentry and controls. Apache has an in-house quality and compliance team to provide all testing and documentation requirements.
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Custom and pressure vessel manufacturers must have accreditation for ASME certification. Compliance with the National Board of Boiler and Pressure Vessel code is required. Pressure vessel manufacturers must also manufacture to ASME material specifications, certificates, and welding qualifications.
Other accreditations are also crucial in the pharmaceutical, life science, and health industries. Confirm all industry compliance standards, including:
• ASME UM
• ASME U
Quality Assurance & Compliance
Verify that the manufacturer has a dedicated quality assurance team. There are significant testing, certifications, and documentation requirements for all global accreditation programs. In-house inspection services are a benefit to ASME projects. Review services that should include:
• Pneumatic testing
• Hydrostatic testing
• Liquid Penetrant (Dye Penetrant) testing
• Saline testing and certificate
• Riboflavin/CIP (clean-in-place) coverage test
• Material Test Reports
• Base metal thickness certificate
• Material trace
• Welder trace
• Ferroxyl test and certificate
• Positive material identification (PMI) and certificate
• Ferrite levels and certificate
• Radiography and analysis
• UT weld testing and certificate
• Turn Over Packet (TOP) as required
The pressure vessel manufacturer must have expertise in the type of vessel and industry experience for the use of the vessel. Critical staff, fabricators, and welders must be ASME certified. All welders must be approved for the weld procedures required to make custom pressure vessels.
Experience and reputation are also significant when developing relationships with inspectors, agencies, and governing officials to keep the compliance process moving forward smoothly.
Service & Support
Above all, assess the service and support provided by the manufacturer. The vessel manufacturer should be able to articulate technical discussions and be open and honest with timelines, cost, and compliance-related issues. Consider other research and questions, such as:
• Is the proposal easy to understand and compare solutions?
• Do you have direct access to the engineer for questions?
• Does the company provide timely and accurate documentation?
• Does the company offer after-market parts and field service?
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There are several reasons why a vessel may need service, however, two main causes why a vessel may need service are either accident or performance related.
In the case of an accident, such as a tool falling into the tank and causing damage; surface scratches and dents can typically be repaired on-site, provided they do not go beyond minimum requirements, with mechanical polishing or hand/wand electropolishing.
Reduced agitator performance or failure is often due to worn parts, improper assembly or a bent or broken shaft. Agitator repairs may be addressed with the agitator manufacturer or the vessel manufacturer, depending on the situation, down-time, and severity of the failure.
When troubleshooting a drop in pressure in a tank or vessel, a typical cause is often related to seals. One sign of seal failure is product coming out of the seal. To help reduce the frequency of an unexpected seal leak occurring, it is recommended to use a good seal maintenance program to solve a lot of pressure / performance issues, such as:
• Seal replacement has been neglected
• Flat spots on seals are a sign for replacement
• Improper or incorrect seals for the outlet
• Nicks, scratches or mishandling of seals
A best practice is to avoid product waste and critical down-time is to inventory seals for all outlets and manage seals in a preventative maintenance program.
It is important to note that any weld repairs to the ASME pressures zones on tanks, require an R-Stamp. The R-Stamp is a certification required by the National Board of Boiler and Pressure Vessels for repair of an ASME tank or vessel.
Depending on the size of the vessel and type of repair, Apache’s service techs may be able to make repairs on site or in some cases, tanks are shipped back to the factory. Apache can provide services including:
• Field service and troubleshooting to all types of stainless and high alloy tanks
• ASME / National Board R-Stamp repair and modifications
• Surface finish repairs
• Non-code repairs and modifications including piping and heat transfer jackets
• Seal and agitation repairs and modifications
• Accessory repairs
• Head and tank shell repairs
• Leak detection
• Audit and service contract available
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Emerging life sciences, and health and wellness product manufacturers must carefully plan budget and start-up costs to launch their products. Many of these entrepreneurs begin production with a general use vessel.
A stainless general use vessel has a lower entry price. Depending on the process and the demand for the product, general-use vessels may serve a small manufacturer very well for many years. Dispensing and storage vessels, vacuum, and low-pressure vessels are common examples of general use applications.
However, when demand outpaces production, the manufacturer may require a vessel that is customized for the processing needs. Here is a case story of a manufacturer that switched from a general use to a custom ASME pressure vessel:
BEFORE: A fast-growing botanical extraction processor was unable to produce the quantity of product needed to fulfill demand. Their process involved an imported general use vessel that was placed in a rudimentary ice bath for temperature control. This process resulted in waste of non-consistent product, constant staffing, and manual intervention to monitor and adjust.
AFTER: Apache's small vessel team provided an ASME processing vessel that completely replaced their batch process. The new vessel was designed with a thermal heat jacket that heated and cooled the product to the exact temperature required for the extraction process. The ASME vessel was jacketed with tri-clamp ferrules and included a site glass and high-pressure sanitary fittings. The vessel has a pickle passivated finish that provides ease of sanitation between batches.
While the price point for a custom manufactured vessel was higher than a general use tank, the ability to quadruple production off-set the cost of the vessel and resulted in a quick return on investment. Apache's custom vessel runs continuously day and night; it eliminated product waste and removed employee monitoring and intervention.
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The steel material used in manufacturing commercial original equipment must fit the performance, pricing, delivery time, and quality requirements for the end-user. Industrial equipment suppliers, like Apache, must leverage relationships with mills and partnering suppliers to manage the constantly changing market. Part of the purchasing program for the stainless material program at Apache, focuses on partnering with quality domestic and foreign suppliers.
Stainless sheet and plate are produced in the United States, which is the majority of Apache’s base material for tanks, vessels and food processing equipment. Also, most Hastelloy and other high-alloy performance metal materials are made in the US. Pipes and fittings on the other hand are primarily from foreign suppliers since domestically there is not enough availability for demand.
Depending on the political climate, import tariffs affect the cost and availability of steel material from China and other countries. Some industries require products from foreign markets that may be a specific sheet, size, and material type, but those industries will pay a premium for it and may be subjected to extended delivery times.
One of the benefits to being a significant user of stainless steel is the relationships with stainless producers and distributors. Apache’s steel venders allocate an allotment of material to Apache, which affords relatively short transactions for supply. When we have a line on repetitive need, we initiate inventory strategies to keep our supply as fluid as possible. Many other components and materials are affected by timing and supply; Apache understands lead times and availability and also leverages relationships to manage delivery to provide the best timing possible.
Our suppliers understand our needs and hold a higher level of steel quality. The relationship and partnership with our steel vendors has strengthened our expectations, with some partnerships lasting up to 45 years when Apache was founded.
Apache uses more than 2000 tons of stainless and high alloy per year. We are in the business of heavy gauge commercial manufacturing of custom equipment for high-compliance industries. Our ability to manage domestic and foreign material as well as price, timing and quality of all material and components is resolved for serving over 100 industries represented by our industrial and commercial processing customers.
There are many industry specific certifications in vessel manufacturing that regulate the construction of a vessel. However, for many types of pressure vessels, ASME certification is required and may be in addition to other industry requirements due to the vessel's geometry and pressure designation. Any tank that meets the requirements of ASME Code Section VIII can be certified. This certification is frequently referred to as "stamped" because the code symbol is most commonly applied using a stamp process. Here are the main differences between ASME U and ASME UM symbols and certification.
ASME Certification with U Symbol
ASME UM Symbol
Note that there may be exceptions to the ASME Certification requirements, depending on your state and local municipality.
Apache manufactures tanks and vessels for compliance and regulated industries, including pharmaceutical, food and beverage, petrochemical, biofuels, chemical and life science. We hold these certifications: ASME U Certificate, ASME UM Certificate, National Board of Boiler & Pressure Inspectors R Certificate, and National Board of Boiler & Pressure Vessel Authorization to Register Certificate.
Questions? Please call and ask for a Sales / ASME Specialist at 920-356-9900.
Apache is a custom manufacturer of tanks and vessels. Due to our customized offering, we want to provide the exact vessel you need; and that might lead to many questions and back and forth responses. If you don't have a specification list, here are 5 recommendations for you to determine when ordering a tank.
1. Determine pressures and temperatures. The design criteria, pressures and temperature requirements will impact material grades, thicknesses, compatibility of fittings and components, and elastomer selection. The following items may help to determine pressures and temperatures.
2. Determine type of certification required. It is advantageous to identify the types of certification and documentation (turn-over packets) that will be required for planning purposes. The following are common requested certificates.
Apache is celebrating one year as a Blue Zones approved worksite. Blue Zones Project is a community-by-community well-being improvement initiative designed to support longer, better lives through permanent changes to environment, policy and social networks. Blue Zones Project is brought to Dodge County in part through sponsorship by the Marshfield Medical Center in Beaver Dam. Dodge County is the first Blue Zones Project demonstration site in Wisconsin.
As a Blue Zones Worksite, Apache has met the official qualifications, including offering benefits and programs that provide employees with a safe and ergonomic work environment, purposeful volunteering and community engagement, support of family, social events, healthy choices, financial well-being and overall mental and health balance.
Some of the past year's activities were a monthly walk-bike-ride share promotion and drawing, quarterly volunteer incentives, organized social activities, sports related and healthy choice prizes at employee events, numerous health and wellness incentives and presentations.
During this unprecedented COVID-19 Pandemic, we are focusing on the overall health and safety of our employee-owners with specific guidelines and schedule adjustments for social distancing, continuous information, resources and flexibility to stay safe.
Emerging market start-ups can have production challenges when their business takes off at a faster rate than planned. Here's a problem that Apache helped to solve.
Problem: A fast-growing botanical extraction processor was unable to produce the quantity of product needed to fulfill demand. Their process involved an imported vessel that was placed in a rudimentary ice bath for temperature control. This process resulted in waste of non-consistent product and constant staffing and manual intervention to monitor and adjust.
Solution: Apache's small vessel team provided an ASME processing vessel that completely replaced their batch process. The new vessel was designed with a thermal heat jacket that heated and cooled the product to the exact temperature required for the extraction process. The ASME vessel was jacketed with tri-clamp ferrules and included a site glass and high-pressure sanitary fittings. The vessel has a pickle passivated finish that provides ease of sanitation between batches.
Apache's vessel runs continuously day and night; it quadrupled production, eliminated product waste and removed employee monitoring and intervention.
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